Remote monitoring system

ABSTRACT

Systems and method for remotely monitoring a factory, manufacturing plant, or other facility are provided. In one implementation, a remote monitoring system comprises a central monitoring station located remote from a food handling facility. The remote monitoring system also comprises a plurality of sensors configured to sense parameters related to operational functions of equipment installed in the food handling facility. Also, the remote monitoring system includes a facility computer located at the food handling facility, wherein the facility computer is configured to receive signals from the plurality of sensors indicative of the sensed parameters. The facility computer is configured to analyze each parameter to determine if the respective parameter falls outside a predetermined normal range and is further configured to communicate an alert to the central monitoring station when the parameters that fall outside the predetermined normal range.

BACKGROUND

In a food handling facility (e.g., food manufacturing plant), many different machines are used to transport food throughout the facility and to keep the food at a proper temperature during transport. Food handling facilities may be configured to transport frozen dinners, frozen chicken, pizzas, and other food products.

It is important to provide maintenance for these machines and other related equipment on a regular basis since machine down-time can result in the loss of time, but, more importantly, may result in significant losses to food products. However, it is difficult to predict when machines in the food handling facility may fail since machinery is often checked infrequently (e.g., once a month). Although more frequent checks can be made, the added cost to companies may be an obstacle.

Currently, sensors and gauges that are installed to sense various parameters of the food handling machinery can be read manually by a maintenance technician, who can then perform any needed maintenance on the machinery. However, if the equipment is checked infrequently, the failure of a machine may occur between maintenance calls. Also, very few people have a working knowledge of the facilities and can provide proper maintenance when needed. Therefore, a need exists for food manufacturing companies to monitor food processing equipment, predict when maintenance will be needed, and provide expert feedback on the operation and required maintenance of the equipment, all being done in a timely manner before the equipment breaks.

In many food handling facilities, spiral conveyor systems may be used. Spiral conveyor systems are designed to freeze/cool/heat-proof many different food items. They run many hours a day to keep up with production and sometimes will run 24/7 for weeks at a time. Many companies do not want to shut these machines down unless absolutely necessary. In the long run, however, problems with the spiral conveyor system machine may cause the machine to be down for days at a time.

Currently, a control panel may be used to show a few items that relate to the spiral. Many of these items are based on prior calculations and are not based on real time data. However, a person must be present at the control panel to see this information. Therefore, a need exists for enabling remote monitoring of food handling facilities by expert technicians and responding to alerts when the equipment in the facility is not operating within desired parameters.

SUMMARY

The present disclosure is directed to systems and method for monitoring equipment installed in a food handling facility or other factory or manufacturing plant. In one implementation, a remote monitoring system comprises a central monitoring station located remote from a food handling facility and a plurality of sensors configured to sense parameters related to functions of equipment installed in the food handling facility. The remote monitoring system may also include a facility computer located at the food handling facility, wherein the facility computer may be configured to receive signals from the plurality of sensors indicative of the sensed parameters. The facility computer is configured to analyze each parameter to determine if the respective parameter falls outside a predetermined normal range and is further configured to communicate an alert to the central monitoring station when the parameter falls outside the predetermined normal range.

In another implementation, a computing system located in a food handling facility comprises a transceiver configured to receive sensed parameter signals from a plurality of sensors that sense a plurality of parameters of pieces of equipment installed in the food handling facility. The computing system also comprises a communication device configured to communicate the sensed parameter signals to a remote central control station via a communication network.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram illustrating a remote monitoring system according to one embodiment.

FIG. 2 is a diagram illustrating the exchange of data throughout the remote monitoring system of FIG. 1, according to one embodiment.

FIG. 3 is a diagram illustrating a perspective view of a spiral according to one embodiment.

FIG. 4 is a schematic diagram illustrating a top view of the spiral of FIG. 3, according to one embodiment.

FIG. 5 is another diagram illustrating a perspective view of the spiral of FIG. 3, according to one embodiment.

FIG. 6 is a schematic diagram illustrating a side view of the spiral of FIG. 3 and showing the location of sensors with respect to the spiral, according to one embodiment.

FIG. 7 is a diagram illustrating a refrigeration control device located outside of a room that contains the spiral of FIG. 3, according to one embodiment.

FIG. 8 is a diagram illustrating food handling equipment to be monitored, according to one embodiment.

FIG. 9 is a diagram illustrating additional food handling equipment to be monitored, according to one embodiment.

FIG. 10 is a diagram illustrating fans of a refrigeration system to be monitored, according to one embodiment.

FIG. 11 is a diagram illustrating a location where room temperature of a spiral room is monitored, according to one embodiment.

FIG. 12 is a diagram illustrating a location where return air temperature of a spiral room is monitored, according to one embodiment.

FIG. 13 is a diagram illustrating a location where plenum temperature is monitored, according to one embodiment.

FIG. 14 is a diagram illustrating a perspective view of a belt of a spiral where belt slack and belt speed are monitored, according to one embodiment.

FIG. 15 is a diagram illustrating a perspective view of a belt of a spiral where an overdrive condition is monitored, according to one embodiment.

FIG. 16 is a diagram illustrating a refrigeration system outside of a spiral room, according to one embodiment.

FIGS. 17-22 are screen shots displayed on a user interface illustrating monitored parameters of the remote monitoring system of FIG. 1, according to various embodiments.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 shows a block diagram of an embodiment of a remote monitoring system 10. The remote monitoring system 10 includes one or more food handling facilities 12 and a central monitoring station 14. The food handling facilities 12 may be located remote from each other. In some embodiments, the food handling facilities 12 may be located within a specific geographical region (e.g., within a county, state, group of states, country, etc.). The central monitoring station 14 may be located within the specific geographical region but remote from the food handling facilities 12. The central monitoring station 14 is configured to remotely monitor the equipment in each food handling facility 12. In this sense, “remote monitoring” may be defined as monitoring the status of machinery and/or equipment within each food handling facility 12 from a location outside of the food handling facility 12 itself.

According to other embodiments, the food handling facilities 12 may alternatively be other types of facilities other than where food is handled. For example, alternative embodiments may include the facilities being a factory or other manufacturing plant where machinery or other equipment is used to manufacture and transport products.

The food handling facilities 12 and central monitoring station 14 may be configured to communicate with each other using a wired or wireless communication network 16, such as the Internet. Thus, the food handling facilities 12 and central monitoring station 14 may comprise processor devices, such as computer systems, for processing data and information and for communicating signals via the communication network 16. As shown in FIG. 1, a facility computer 18, which may be installed within each food handling facility 12, is configured to communicate with a maintenance computer system 20 located at the central monitoring station 14.

Each food handling facility 12 includes machinery 22 or other equipment that is used within the food handling facility 12 for producing food products, transporting the food products, maintaining a temperature of the food products, etc. For example, some pieces of equipment of the machinery/equipment 22 may include conveyor systems, spiral conveyors, conveyor belts, refrigeration systems, refrigeration fans, motors for moving drums, motors for moving towers, etc. Other machinery/equipment 22 may be used for handling food products, as will be known in the art and as described in more detail below.

The remote monitoring system 10 provides a maintenance system that is efficient and cost effective. The system 10 includes the installation of sensors 24, where needed, of many of the various pieces of equipment 22 in the food manufacturing facility or food handling facility 12. Some of the sensors 24 may need to be powered by batteries.

Installation of the facility computer 18 at the facility 12 may also include equipping the facility computer 18 with a transceiver for wirelessly receiving sensor signals from the sensors 24 and a router for enabling communication over the communication network 16. The facility computer 18 may also include a user interface for displaying sensor data.

The facility computer 18 can then remotely communicate with the plurality of sensors 24 installed throughout the facility 12. A software program running on the computer 18 may be designed to analyze the operation of the equipment 22 in an up-to-date manner. In some cases, the computer 18 may ping the sensors 24 at regular intervals to request a sensor reading. For example, the sensors 24 may be requested to sense a particular property once a week, once a day, once an hour, once a minute, or other time periods, depending on the type of sensor 24 being used and/or the equipment 22 being monitored. For example, the facility computer 18 may comprises a WSDA-200 device, which can be used to ping the sensors 24 at regular intervals to obtain the sensor data.

FIG. 2 is a diagram showing the communications between the various components of the remote monitoring system 10 of FIG. 1. A food handling facility 12 may include a number of control panels 30 that are installed near the equipment 22 (e.g., spiral conveyor system). The control panels 30 may receive sensor data from the sensors 24 and communicate the data, using an Internet gateway 32, to a cloud server 34 (e.g., the maintenance computer system 20 shown in FIG. 1).

An operator can remotely control the settings of the equipment 22 at the facility. Also, the operator can change the thresholds based on knowledge of the systems. This may be done on a case by case basis. The control panels 30 installed at the facility may be configured such that they can only allow certain authorized people to make changes to the system. Therefore, a user cannot make decisions about controls without proper authorization. A code may be used to keep unauthorized users from making changes to the settings.

The cloud server 34 may be configured to analyze sensor data to determine if parameters are within predetermined thresholds. If not, the cloud server 34 can communicate alerts, alarms, or other messages to the appropriate people to inform them of the status of the equipment 22. The cloud server 34 uses another Internet gateway 36 to communicate with the food handling facilities 12 where maintenance issues may exist or with maintenance technicians via laptop computers 38, mobile devices 40, and/or personal computers 42, which may be mobile devices that the technicians carry with them or devices located at the central monitoring station or other fixed location.

FIG. 3 is a diagram showing an embodiment of a spiral conveyor system (“spiral”). FIG. 3 shows a cut-away of a refrigerated room 52 where the spiral 50 operates. A refrigeration system 54, positioned outside the room 52, is configured to supply cool air throughout the room 52 to keep the spiral 50, and any food products being conveyed on the spiral 50, cool or frozen. Air flow from the refrigeration system 54 may be directed over the top of the spiral 50. Coils of the refrigeration system 54 may be positioned beside the fans 56 in this embodiment.

Depending on the orientation of the spiral 50, the spiral 50 may be configured to receive the food products either at a top portion or a bottom portion. Then, the food products are then spiraled along the spiral 50 in a clockwise or counterclockwise direction, spiraling downwards or upwards, and then exiting the spiral 50 at the bottom portion or top portion of the spiral 50.

FIG. 4 is a schematic diagram showing a top view of an embodiment of the spiral 50 of FIG. 3. The schematic of FIG. 4 also includes the locations of sensors for sensing various parameters. The conveyor system includes an input conveyor 60 that leads food products to the spiral 50 and an output conveyor 62 that leads the food products away from the spiral 50.

The input conveyor 60 includes a tension tower gearbox and motor 64. A sensor 66 is used to monitor the tension tower gearbox and motor 64 and to measure belt speed.

The spiral 50 includes a main drive gearbox and motor 68. A sensor 70 is installed to monitor the main drive gearbox and motor 68. A top and bottom bearing 71 of the main drive gearbox and motor 68 is monitored by top and bottom bearing sensors 72. In addition, an overdrive sensor 74 may be positioned on the spiral 50.

The refrigerated room 52 includes fans 76 for circulating cool air throughout the room 52. Fan motor sensors 78 are installed for sensing fan speed of the fans 76. Also, temperature sensors are installed throughout the room 52 to measure temperature. For example, the temperature sensors may include a plenum temperature sensor 80, a return air temperature sensor 82, and a room temperature sensor 84.

A control panel 86 may be provided outside of the refrigerated room 52. The control panel 86 may be configured to allow an operator to control the settings of the refrigeration system and to monitor temperatures read by the sensors 80, 82, 84. The control panel 86 may also display the status of the other equipment monitored by the sensors 66, 70, 72, 74, 78.

FIG. 5 is a diagram of the spiral 50, which is configured as a down-running spiral and has a layout that transports food in a downward spiral direction. The input conveyor 60 or “in-feed” is where the food product comes in and the output conveyor 62 or “out-feed” is where the food product goes out. The spiral 50 includes a cage or drum, which pulls the belt. The tension tower motor and gearbox 64 are configured to operate with a tension tower 90, which is configured to store the belt slack.

FIG. 6 is a schematic diagram showing a side view of the spiral 50 along with the location of various sensors. In addition to the sensors mentioned above with respect to FIG. 4, the embodiment of FIG. 6 also includes a top bearing sensor 72 a, a belt flip sensor 94, a bottom bearing vibration sensor 96, a main drive gearbox vibration sensor 98, and main drive motor vibration sensor 100. Sensors 98 and 100 may detect frequency (in Hertz) of the vibration.

Conventionally, a maintenance technician within a food handling facility 12 may inspect the machinery/equipment 22 manually to determine if the pieces of equipment (e.g., spiral and other related components) are operating properly. However, in the present application, a plurality of sensors 24 are installed throughout the food handling facility 12 for sensing various operational parameters of the machinery/equipment 22. The sensors 24 are installed in order to be able to properly obtain specific parameters related to the operating functions of the machinery/equipment 22. For example, the sensors may be configured to measure or sense parameters such as belt speed, drum speed, tower speed, dwell time (i.e., time that a food product remains at a certain location within the facility), drum frequency (i.e., electrical frequency used for operating a drum), drum current (i.e., electrical current used for powering the drum), tower frequency, tower current, fan speed, room temperature, return air temperature, plenum temperature, set point temperature, gear box vibration, fan motor vibration, bearing vibration, belt slippage (i.e., condition in which a belt slips), belt slack, belt flip, motor overdrive, torque, etc.

From the sensed parameters obtained, the software program running on the facility computer 18 can determine, based on predetermined thresholds, whether a machine is operating outside of those thresholds. For example, a vibration sensor may sense when a machine is experiencing a large vibration that may indicate that the machine is not operating properly or is close to failure. In order to prevent failure, these out-of-spec detections can be communicated to the central monitoring station 14. The central monitoring station 14 is configured to monitor multiple food manufacturing facilities 12 at one time. A team of maintenance experts may therefore be available at the central monitoring station 14 to provide expert maintenance decisions based on the monitored equipment.

In some embodiments of the remote monitoring system 10, processing of sensor signals may occur at the food handling facility 12 itself and/or at the control monitoring station 14. For instance, the maintenance computer system 20 may also run a software program for receiving sensor signals to determine if the machinery/equipment 22 is operating properly.

The central monitoring station 14 may include one or more servers configured to communicate with the facility computers 18 located at each food handling facility 12. The servers can receive the sensor data and/or alerts of machinery 22 that is outside of normal operating parameters. Some data may be analyzed, either by software running on the servers of the maintenance computer system 20 or by maintenance experts who can remotely monitor the machinery 22. Decisions for action may be made by the servers or by the maintenance experts.

In some embodiments, the servers may provide control signals to the food handling facilities 12 to control the operation of the machinery 22. For example, if a measured parameter indicates that a certain machine should operate at a slower speed to prevent damage to or failure of the machine, the server can remotely control the machine to run at a slower speed. In other embodiments, a maintenance expert may be required to communicate with a person at the food handling facility 12 to make adjustments to the machines as needed to prevent damage or failure. In still other embodiments, the maintenance expert may visit the facility 12 or deploy another expert who may be in or near the facility 12 to make any necessary adjustments or maintenance actions.

Upon analyzing sensor data, it may be necessary that certain equipment 22 may need to be replaced. In this case, the maintenance expert may work with an employee at the facility 12 to schedule for an installer to transport and/or install replacement parts and equipment.

When equipment is detected as being out-of-spec, an alert can be communicated to the central monitoring station 14. Alerts can be communicated automatically or manually by email, text message, phone message, or by other suitable communication methods. In some cases, a response communication can be provided automatically or manually from the central monitoring station 14 back to the food handling facility 12. The response communication may include a solution to a problem and can be sent via email, text, phone, or other methods.

In operation, the remote monitoring system 10 may require the administrators of each food handling facility 12 to enter into a contract with the administrators of the central monitoring station 14. Therefore, in order to receive the services of remote monitoring and/or maintenance, managers or other personnel of the food handling facility 12 may sign a contract for services with the maintenance technicians of the central monitoring station 14. When a food handling facility 12 is signed up to receive services, a technician (e.g., electricians and/or other workers) from the central monitoring station may be dispatched to the location of the food handling facility 12 to determine all the sensors 24 that may need to be installed to properly monitor the equipment 22. Also, the sensors 24 will need to be capable of communicating remotely with the facility computer 18, which may also be installed at the food handling facility 12, if needed. Then, when the sensors 24 are up and running, the facility 12 can be remotely monitored.

The sensors 24 installed in the food handling facility 12 may include any type of sensor for sensing any type of parameter. In some embodiments, sensors may be configured for sensing overdrive of a motor, slippage of a belt, belt speed of a conveyor belt that conveys food products, belt slack, a belt flip condition, drum speed of a drum used to drive the belt, dwell time, an operating electrical frequency (in Hertz), an operating electrical current (in Amps), temperature, vibration, motion, torque, gap counting, belt tightness, and others.

FIG. 7 shows a control panel 104 outside of a freezer box or freezer room 52. The spiral, coils (refrigeration), etc. are all enclosed within the freezer box in the area beyond the door 106.

An overdrive condition refers to a condition when a drum, configured to outrun a belt by a certain amount, is not operating with a correct tension. For example, a belt may have a width of 36 inches and a cage of the drum may be configured to outrun the belt by 51 inches. The difference in distance can be measured to determine overdrive. The drum includes a number of bars. A sensor 24 can be set up next to the bars, so that when the belt comes around, a distance can be measured to determine how far the drum is ahead of the belt.

The conveyor belt system may be used for conveying food products throughout the food handling facility 12. A “spiral” is a belt system that has one continuous belt or a sequence of belts that form an upward or downward directed spiral. For instance, in a downward spiral belt, the food enters at a top of the spiral and is conveyed downward in a spiral fashion. For example, when food is cooked and needs to cool off for a predetermined length of time, the food can be conveyed in a refrigerated spiral system and remains cool during the conveying process before the food is packaged.

Belt position is another factor that is monitored. If a belt gets out of alignment, the belt system may tear the belt apart, causing many problems. In some instances, a torn belt may shut the entire operation down for days until it can be fixed.

The drum speed and belt speed are normally based on the electrical frequency (in Hertz) and the electrical current (in Amps) applied to the system. However, the frequency and current can also be monitored to determine if a spike in current occurs, which can be an indication of a problem, such as an obstruction in the system that is keeping the belt from moving properly. When a current spike is detected, an alert can be provided. In some systems, an automatic shut-down switch may be used to shut the conveyor system down when a problem is detected, such as a current spike. However, if such a switch is not installed, the sensors 24 for monitoring frequency and current can be used to provide an alert.

FIG. 8 shows where sensors may be placed to detect vibration, heat, electrical frequency, and electrical current. A main drive motor 110 and gearbox 112 are shown. Vibration and heat sensors (vertical and horizontal vibrations), Hertz, and Amp draw are detected by sensors. Normally, Hertz and Amp draw may be shown in a control panel. However, the present invention allows this information to be shown on a computer or on a mobile phone. The bottom bearing 114 is also shown. Vibration and heat sensors (vertical and horizontal vibrations) can be monitored with sensors.

A sensor for monitoring the Main Drive Gearbox 112 may be installed. The main drive gearbox sensor may also be a G-Link 200 vibration and heat sensor, which can detect vertical and horizontal vibrations. Once normals are monitored, boundaries can be set. This sensor, once set, will read about every hour.

A current transformer can be installed on the electrical lines feeding the main drive gearbox. The V-Link 200 analog input sensor may be installed for reading the current transformer and recording the amp draw. An analog output will be installed on a variable frequency drive (VFD) which controls the main drive gearbox. The V-Link 200 sensor will read the frequency (Hertz) from the analog output sensor. Once set, the Amps and Hertz parameters will be read every 30 minutes.

A sensor for monitoring the Main Drive Motor 110, such as a G-Link 200 vibration and heat sensor, may be installed. Vertical and horizontal vibrations are detected with this sensor. Once normals are monitored, boundaries are set. This sensor, once set, will read every hour. The V-Link 200 analog input sensor may be configured for reading the current transformer installed on the electrical lines feeding the main drive motor to record the amp draw. An analog output will be installed on the variable frequency drive (VFD) which controls the main drive motor. The V-Link 200 sensor will read the frequency (Hertz) from the analog output sensor. Once set, the Amps and Hertz parameters will be read about every 30 minutes.

Sensors can also be installed for monitoring Overdrive. On each spiral, there is a main drive gearbox and motor, with a center shaft installed into the gearbox 112 and a drum mounted to the center shaft. The gearbox 112 turns the shaft, which turns the drum. First, an “ideal/mathematical” rotational speed of the drum can be calculated. In order to do this, the sensor may be used to detect the speed of the motor. The ratio of the gearbox 112 and the radius of the drum are known parameters. A laser sensor may be installed above the outside of the belt, on the top beam of the spiral. The laser sensor counts the amount of openings in the belt in a given time. This will allow the software on the facility computer 18 or maintenance computer system 20 to calculate the belt speed for the outside of the belt. The difference of the belt speed and the “ideal” rotational speed of the drum equals the overdrive. If the belt slows down, a signal will be sent from the facility computer 18 and/or maintenance computer system 20 to the drum to increase its speed to get the belt back into its normal settings. Sensed parameters can be determined as being average (or within a range of an average) or being out-of-spec.

FIG. 9 shows a tension tower motor and gearbox 120. Vibration and heat sensors are used to measure Hertz, and Amp draw. Normally, Hertz and Amp draw may be shown in a control panel. However, the present invention allows this information to be shown on a computer or mobile phone.

The spiral conveyor system includes a tension tower. The tension tower is a device that provides the slack of the belts. The tension tower drives the belt to keep it tight against the drum so that the drum can properly drive the belt, which is the reason that the drum operates faster than the belt. Adjustments can be made to the drum to make sure the belt has the correct tightness or tension.

FIG. 10 shows individual fans 124. Vibration and heat sensors may be positioned on or near the fan motors to measure fan speeds, Hertz, and Amp draw. Control panel currently shows Amp draw of each fan and fan speed in percentage (for example 25%, 50%, 75%, 100%). This information may be available in the present application from a computer or smart phone.

FIG. 11 shows an area where room temperature may be measured. For example, temperature sensor 84 (shown in FIG. 4) may be used for sensing Room Temperature and may be a McMaster Carr RTD Probe that reads the temperature before the air hits the food product. This probe is placed about one foot from the freezer box front wall and may be hung from the ceiling.

FIG. 12 shows an area where return air temperature may be measured. For example, temperature sensor 82 (shown in FIG. 4) may be used for sensing Return Air Temperature and may be a McMaster Carr RTD Probe that reads the return air temperature. This probe is placed about one foot in front of the coils and is hung from the ceiling of the freezer box.

FIG. 13 shows an area where plenum temperature may be measured. For example, temperature sensor 80 (shown in FIG. 4) may be used for sensing Plenum Temperature and may be a McMaster Carr RTD Probe. These probes may be placed about one foot behind the coils and may be hung from the ceiling of the freezer box.

FIG. 14 shows a Belt Slack Loop Sensors 130. Some sensors 130 may already be used to detect belt slack, but they are not incorporated in the remote monitoring system 10 to alert technicians via phones or computers, but may communicate to a control panel connected to the unit. A Belt Speed sensor 132 may be installed. The sensor 132 may be used to alert technicians by phones/computers (in addition to the control panel connected to this unit). The belt speed sensor 132 can measure belt speed as follows: A cylindrical proximity sensor may be used to measure how many times a shaft spins. This number is then used with the circumference of the shaft to find the distance traveled. Belt speed can be calculated by taking the distance traveled and divide that by time. The belt speed is usually calculated in the units of feet per minute.

The belt slack loop sensors 130 may be proximity switches. When a roller of the conveyor system contacts the proximity switch, the machine may be shut down. On some occasions, maintenance workers may void the proximity switch to prevent the machine for shutting down, even when it may be necessary to do so. Unfortunately, this may result in serious damage to the machine.

A proximity sensor may also be used for a belt flip sensor. A rod goes up each layer of the belt on the spiral belt system. If the belt starts to rise, it will lift the rod until it contacts or leaves (disconnects from) the proximity sensor (depending on the type of proximity sensor in use) which causes the proximity sensor to switch the machine off or provide an alarm.

FIG. 15 shows a laser sensor used to detect overdrive. According to some embodiments, overdrive can be determined using a laser located on an outer edge of the system next to the belt. The laser can be used to count the number of gaps in the belt. Based on knowledge of the belt system, the monitoring system will know how many gaps per minute should be normal. If the gap count is below a predetermined number, that is, when the belt slows down, a signal may be provided to indicate that the belt speed needs to be increased by speeding up the drum. This can be done electronically from the remote location of the central monitoring station 14.

This is an improvement over conventional systems in which the belt speed is set and left at that speed until it may be checked again in a week or so. However, since the belt may get tighter as the days pass, it is important to continually monitor the belt speed, as is done in the present invention. Also, this allows the cage speed to be constantly readjusted, as needed, to maintain a proper speed.

FIG. 16 shows a refrigeration system 140 with fans 142, positioned outside a refrigerated room where the spiral may be located. Fan Motor sensors can also be used to measure the speed of the fans 142. For example, there can be anywhere from 3 to 12 fans 142 in a system, where each fan 142 may have a set of sensors. For example, a G-Link 200 sensor may be used for measuring both vibration and heat. Thus, these sensor 24 for measuring vibration and heat may be installed. Vertical and horizontal vibrations are also detected with this sensor. Once normals are monitored, boundaries are set. This sensor, once set, may be read every hour (or other suitable time interval).

A current transformer may be installed on the electrical lines feeding the fan motors within the food handling facility 12. For example, the V-Link 200 analog input sensor may be installed. The V-Link sensor will read the current transformer to record the amp draw. An analog output will be installed on the variable frequency drive (VFD), which controls each fan motor. The V-Link 200 sensor will read the frequency (Hertz) from the analog output sensor. Once set, the current (Amps) and frequency (Hertz) may be read every 30 minutes (or other suitable time interval). The fan speed is taken from the Hertz read on the V-Link 200 sensor. The current Hertz of the fan divided by the total possible Hertz of the fan times one hundred percent equals the fan speed as a percentage.

A refrigeration system is often part of food handling facilities 12. The refrigeration system may include ammonia or Freon running through coils to create a cooling effect. Also, fans are used to move cool air throughout the spiral, refrigerated room, or other areas where refrigerated air is needed. The fans of the conveyor system can also be monitored. Fans can be controlled individually using the present invention. Fan speed can be increased or decreased as needed, either from a local control setting or from a remote monitoring location. Air is drawn in through one side of the coil and exits through the other end of the coil.

The room temperature refers to the temperature before the refrigerated air reaches the food product on the spiral. Temperature can also be monitored inside the freezer box, where the food product is being conveyed. Return air temperature is the temperature of the air leaving the product. Normally, the difference in the room temperature and the return air temperature is a certain amount, such as about 15 degrees. If the temperature difference is not within a set range, the facility computer 18, maintenance computer system 20, and/or a technician monitoring the sensor parameters, may determine that the belt system is too fast or too slow, that the refrigeration system is too hot or too cold, or that the fan speed is too fast or too slow. The plenum temperature is the temperature coming off of the coils, which is typically the coldest part of the refrigeration system. The set point temperature is the temperature at which the room temperature is set. This can be used to turn the coils on and off. Temperatures within a freezer box or within other refrigerated areas of the food manufacturing facilities may be maintained well below freezing, such as 20-30 degrees below zero Fahrenheit.

Embodiments of the present application include a belt system or spiral belt system. In other embodiments, other parameters can be monitored with respect to other types of conveying systems. For example, some food products, such as turkeys, can be conveyed using hooks and chains, where the turkeys are hung from the chains. However, the movement of the food product (i.e., turkeys) can cause the chain to get out of synchronization with a driving system. Also, a warning can be provided to indicate that the chain is about to wear out. However, conventional monitoring systems do not provide warnings to remote monitoring locations to allow a central expert technician to monitor these parameters. In the present application, a maintenance technician at the central monitoring station 14 can monitor these and other parameters remotely to determine when the chain is out of sync or needs to be replaced.

One or more transceivers in the facility computer 18 may be used to receive wireless signals for the various sensors 24 throughout the facility 12. The expert technician may set the time intervals for when the sensors 24 are configured to sense and transmit data to the facility computer 18. The technician can remotely change the time intervals as needed. For example, if one sensor 24 is detecting a parameter every hour, but the technician determines that the parameter needs to be sensed every 15 minutes, that time interval can be changed remotely.

Software is installed in the facility computer 18 for obtaining the sensor data from each of the sensors 24. Also, the software compares the data with threshold values to check if the parameters are within the proper specification. If not, then alarms can be communicated to the central monitoring station 14 or automatic shut-down procedures can be executed. When the maintenance computer system 20 at the central monitoring station 14 receives data and/or alerts, this information is sent to an expert technician, who can then determine how to resolve any issues. The expert technician may use his expertise in the field of food manufacturing facilities (or other factories or plants) to determine how the data is to be used. In some cases, it may be best to wait to see if a condition lasts a particular amount of time; otherwise, the systems may be over-maintained. Also, the expert technician may give a warning to the food company that a certain piece of equipment 22 may be near the time that it needs to be replaced. In this way, the company will know that they have a certain amount of time (e.g., a few months) to find a replacement for the equipment that is near the end of its life.

Regarding belt flip sensors, if a belt has already flipped, it is probably too late to avoid damage to the belt or the conveyor system. In conventional systems, this condition is usually not detected. Even when belt condition is monitored manually, there is usually no warning of the condition. Therefore, a company may have a flipped belt without knowing it. The machine may even shut down without the company's knowledge. With the belt flip sensor of the present application, a detection can be made right away to prevent additional damage to the system or food products.

Before the belt flips, another sensor (e.g., laser sensor) is configured for counting the gaps in a belt, which can tell that the belt is getting tighter and is slowing down. When the belt slows down, it gets tighter. When it gets too tight, it is more likely to flip. When too tight, a signal can automatically be sent to the drum to speed up, which should correct the problem and avoid damage. Therefore, some sensors can detect before the belt flip condition occurs.

The remote monitoring system 10 of the present application can monitor the whole system and allow the food handling facilities 12 to run as long as possible. The system 10 can detect a problem before it happens so that the machine's downtime can be minimized. When machinery 22 fails, the central monitoring station 14 can detect the failure and have parts ordered and ready in addition to scheduling work crews to do repairs. This will eliminate waiting on emergency crews to arrive and having to wait for the parts to arrive.

One type of sensor can be used to monitor a top bearing. For example, a Top Bearing sensor 24, such as a G-Link 200 vibration and heat sensor, may be installed with the top bearing. Vertical and horizontal vibrations are detected with these sensors. Once normals are monitored, boundaries can be set. This sensor, once set, will read about every hour (or other suitable time interval).

Another sensor may be a Bottom Bearing sensor, such as a G-Link 200 vibration and heat sensor, which may be installed with the bottom bearing. Vertical and horizontal vibrations are detected with this sensor. Again, once normals are monitored, boundaries are set, and this sensor, once set, will read about every hour.

A Tension Tower Gearbox sensor, such as a G-Link 200 vibration and heat sensor, may be installed. Vertical and horizontal vibrations are detected with this sensor. Once normals are monitored, boundaries are set. This sensor, once set, will read about every hour. A current transformer may be installed on the electrical lines feeding the tension tower gearbox. A V-Link 200 analog input sensor may be installed, which reads the current transformer to record the amp draw. An analog output will be installed on the variable frequency drive (VFD) which controls the tension tower motor. The V-Link 200 sensor will read the Hertz from the analog output sensor. Once set, the Amps and Hertz will be read every about 30 minutes.

A Tension Tower Motor sensor, such as a G-Link 200 vibration and heat sensor, may be installed. Vertical and horizontal vibrations are detected with this sensor. Once normals are monitored, boundaries are set. This sensor, once set, will read every hour. A current transformer is installed on the electrical lines feeding the tension tower motor. The V-Link 200 analog input sensor is installed. The V-Link sensor will read the current transformer to record the amp draw. An analog output will be installed on the variable frequency drive (VFD) which controls the tension tower motor. The V-Link 200 sensor will read the hertz from the analog output sensor. Once set, the amps and hertz will be read every 30 minutes.

A Belt Speed sensor may be installed. A UHMW roller with a set screw is placed on the end of the tension tower drive shaft. A Belt Speed sensor is placed on the tension tower for counting the number of times it sees the set screw over a given time. The tension tower drive shaft drives the belt with a set of sprockets. With one rotation of the tension tower drive shaft, a distance that the belt travels is known based on the circumference of the sprocket. The circumference of the sprocket times the number of times the shaft rotates divided by twelve gives us the distance travelled in feet. The distance travelled in feet divided by the given time (in minutes) gives us the belt speed in feet per minute.

A Tension Tower Upper Limit sensor may be a proximity switch placed on the tension tower at the upper limit. A dead roller shaft moves up and down to adjust the amount of slack in the belt. The proximity switch reads the metal from the dead roller shaft. When the proximity switch reads the metal, it shuts off the machine. This information with a date and time stamp is logged.

A Tension Tower Lower Limit sensor may be another proximity switch placed on the tension tower at the lower limit. The dead roller shaft moves up and down to adjust the amount of slack in the belt. The proximity switch reads the metal from dead roller shaft. When the proximity switch reads the metal, it shuts off the machine. This information, with a date and time stamp, is logged.

Regarding the facility computer 18, a router may be installed, such as an EWON Cosy 131, which is a wireless router that may be installed in a user-interface, such as a control panel. The router allows the facility computer 18 to access the communication network 16 or Internet. The Internet access allows the sensors 24 to communicate with a gateway and the software of the facility computer 18 to communicate with the maintenance computer system 20 or cloud server.

A gateway, such as a WSDA-200-USB, may be installed via a USB port on the facility computer 18. Once all of the information is gathered from the sensors 24, the gateway can input the sensor data into the software running on the facility computer 18.

A computer may be located in a control panel of each spiral with software that records and stores all of the readings from the sensors 24. The software on this computer can then download all of the information to the maintenance computer system 20 or cloud server.

The remote monitoring system 10 will be able to detect issues with parts within the spiral before they completely fail and cause the machine to be down. Throughout the week, the overdrive needs to be adjusted. Currently, there is no way to update the overdrive automatically in real time as the machine is running. Adjusting the overdrive multiple times throughout the week as the machine adjusts will provide minimal wear on the machine. Maintenance technicians and other operators at the central monitoring station 14 will get real time information from the food handling facilities 12 and be able to monitor the systems from any remote location. The technicians will know when there has been an issue and will be able to keep an eye on the machinery 22.

The remote monitoring system 10 monitors the whole system and allows the plants or facilities 12 to run as long as possible. The central monitoring station 14 detects problems before they happen so as to minimize machine 22 downtime. The central monitoring station 14 and/or technicians at the central monitoring station 14 can have parts ordered and ready in addition to scheduling work crews to do the repairs. This will eliminate waiting on emergency crews to arrive and having to wait for the parts to arrive. Overdrives can be adjusted to compensate and allow optimal machine performance.

The remote monitoring system 10 may also be related to remotely monitoring facilities other than food manufacturing facilities. For example, sensors may be installed in other manufacturing facilities, assembly lines, flow production facilities, factories, etc. In the same way, sensed conditions of machinery in these other facilities may be communicated to a remote central monitoring station 14, where the sensor data can be analyzed in order that a proper response can be performed, such as maintenance, repairs, part replacement, adjusting operational settings of machinery, etc.

FIGS. 17-22 are screen shots showing various sensed parameters obtain in the remote monitoring system 10. The screen shots show examples of parameters that may be displayed on a control panel or other user interface on the facility computer 18 and/or maintenance computer system 20. FIGS. 17-22 show the status of the various sensors. Charts, tables, graphs, and other features of the status of the sensors can be displayed on the control panel. In some embodiments, the parameters may be displayed on a computer or server, such as on the facility computer 18 or maintenance computer system 20. Alternatively, the parameters may be configured for display on a mobile device, such as a mobile phone, smart phone, tablet, etc. In this way, the charts, tables, and graphs of the parameters may be wirelessly transmitted to a mobile device associated with a maintenance technician in order that the technician can access the information while roaming (e.g., while away from the central monitoring station 14). FIGS. 17-22 show different variables of the machinery/equipment 22 used in the food handling facility 12.

FIG. 17 As shown in the upper left corner of the screen shot of FIG. 17, fans can be monitored. Also, as shown in the bottom left corner, a spiral drum current (in Amps) can be monitored. A tension tower of the spiral and its current can be monitored. A dwell time, which is the amount of time that the food product stays on the spiral, can be monitored. The belt speed of the spiral can be monitored.

In the upper right corner, refrigeration temperatures are monitored. Other conditions are also monitored, as shown in FIG. 17.

In addition to simply displaying the variables on the control panel, alerts can be monitored when the variables fall outside of predetermined thresholds. When one or more variables are out-of-spec, an email, text message, or other communication can be provided to the expert maintenance person to draw attention to the issue.

Some facilities may have a computing system having a control panel showing similar parameters of the machinery. However, according to embodiment of the present invention, these displayed variables can furthermore be monitored at the facility or at the central monitoring station 14 to determine if the variables are out-of-spec. Also, communication can be provided to alert a maintenance expert when actions may be required.

FIG. 18 shows a screen shot of the control panel showing drum speed and tower speed. Sensors can be installed with each electric fan, such as on the fan motors, to monitor the fans. A motor of a cage can be monitored, as well as a motor that pulls the belt.

FIG. 19 shows a screen shot of the operations of the refrigeration system. Parameters such as dwell time and fan speed of each of the fans may be displayed.

FIG. 20 shows another screen shot related to the refrigeration system. In addition, this display may include Amps, Frequency, status, DC bus voltage of the different fans.

FIG. 21 shows another screen shot for showing the status of various pieces of equipment and the status of alarms. An electric motor drives a gear box. The gear box drives a drum. The drum drives a belt. The gear box is normally geared very low. Oil is provided in the gear box to reduce friction. However, the gear box may still experience vibration during normal operation. When the oil level is low or when the teeth of the gears wear down, the vibration may increase. As the bearings wear, the vibration may increase. With an increase in vibration being detected, the expert maintenance technician may realize that something may be wrong, but the exact cause of the vibration may be unknown. In this case, several actions may be taken to resolve the issue. For example, the gearbox may need to be replaced, oil may need to be added, water may be present in the gearbox, gears may need to be replaced, etc. Vibration may be detected as being out-of-spec when it reaches a certain threshold.

According to some methods, the system may be analyzed for a certain amount of time (e.g., two weeks) to determine the regular vibration values of the system to determine what the average is. This may be a factor of the type of gear box being used, the age of the gear box, etc. When the system first starts up, there will be a regular spike in vibration, which can be ignored since it is a regular part of the start-up process.

The vibration can also be monitored with respect to a change over time. For example, if the vibration increases somewhat steadily over a certain period of time (e.g., one hour, one day, etc.), this change can be detected as a potential problem that may need attention.

FIG. 22 shows a list of all the sensors that can be displayed on the computer or mobile device of the expert technician. The list includes a name of the sensor and the location of the sensor in the system. The chart also shows the battery status of the sensors, where green bars represent the charge remaining on the battery. An alert can be provided when a battery reaches a low charge level. Also, the chart indicates a status of a Wi-Fi signal between the sensor and a computing system, which may include routers, wireless modems, network switches, and/or computers. The computing system of the facility can be connected via a wide area network (WAN), such as the Internet, to a server at the central monitoring station 14. 

What is claimed is:
 1. A remote monitoring system comprising: a central monitoring station located remote from a food handling facility; a plurality of sensors configured to sense parameters related to operating functions of equipment installed in the food handling facility; and a facility computer located at the food handling facility, the facility computer configured to receive signals from the plurality of sensors indicative of the sensed parameters; wherein the facility computer is configured to analyze each parameter to determine if the respective parameter falls outside a predetermined normal range; and wherein the facility computer is further configured to communicate an alert to the central monitoring station when at least one of the parameters falls outside the predetermined normal range.
 2. The remote monitoring system of claim 1, wherein the central monitoring station comprises a control panel configured to display at least one of the sensed parameters.
 3. The remote monitoring system of claim 1, wherein the central monitoring station is configured to provide notifications to at least one technician that an action is needed to keep a sensed parameter within the predetermined normal range.
 4. The remote monitoring system of claim 3, wherein the needed action includes adjusting a setting of a piece of the equipment.
 5. The remote monitoring system of claim 4, wherein the piece of the equipment is configured to be adjusted remotely by the at least one technician.
 6. The remote monitoring system of claim 3, wherein the central monitoring station provides the notifications to the at least one technician via email or text message.
 7. The remote monitoring system of claim 1, wherein at least one of the sensors is battery-powered and is configured to wirelessly transmit the signals indicative of the sensed parameters to the facility computer.
 8. The remote monitoring system of claim 1, wherein the sensors are configured to sense the parameters on a periodic basis.
 9. The remote monitoring system of claim 1, wherein the food handling facility comprises a spiral conveyor system for transporting food products.
 10. The remote monitoring system of claim 1, wherein the equipment includes at least one of a conveyor belt, a fan, a drum motor, a tower motor, and a refrigeration system.
 11. The remote monitoring system of claim 1, wherein the sensors are configured to sense at least one parameter selected from the parameters of belt speed, drum speed, tower speed, dwell time, drum frequency, drum current, tower frequency, tower current, fan speed, room temperature, return air temperature, plenum temperature, set point temperature, gear box vibration, fan motor vibration, bearing vibration, gear box heat, fan motor heat, bearing heat, belt slippage, belt slack, belt flip, motor overdrive, and torque.
 12. A computing system located in a food handling facility, the computing system comprising: a transceiver configured to receive sensed parameter signals from a plurality of sensors that sense a plurality of parameters related to operational functions of pieces of equipment installed in the food handling facility; and a communication device configured to communicate the sensed parameter signals to a remote central control station via a communication network.
 13. The computing system of claim 12, further comprising a processing device configured to analyze the sensed parameters signals to determine an alert condition.
 14. The computing system of claim 13, wherein the communication device is configured to transmit the alert condition to the remote central control station.
 15. The computer system of claim 12, further comprising an actuator, wherein the communication device is configured to receive an action signal from the remote central control station, and wherein the actuator utilizes the action signal to adjust a setting of at least one of the pieces of the equipment.
 16. The computer system of claim 12, wherein at least one of the sensors is battery-powered and is configured to wirelessly transmit the sensed parameter signals to the transceiver.
 17. The computer system of claim 12, wherein the food handling facility comprises a spiral conveyor system for transporting food products.
 18. The computer system of claim 12, wherein the pieces of equipment includes at least one of a conveyor belt, a fan, a drum motor, a tower motor, and a refrigeration system.
 19. The computer system of claim 12, wherein the sensors are configured to sense at least one parameter selected from the parameters of belt slippage, belt speed, drum speed, tower speed, dwell time, drum frequency, drum current, tower frequency, tower current, fan speed, room temperature, return air temperature, plenum temperature, set point temperature, gear box vibration, fan motor vibration, bearing vibration, gear box heat, fan motor heat, bearing heat, belt slack, belt flip, motor overdrive, and torque. 